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ZF S5-42 Swap confusion

 
  #31  
Old 01-11-2016, 06:57 PM
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Originally Posted by EPNCSU2006 View Post
A couple of tidbits from my swap experience:

You can use the original master cylinder with a new hydraulic line to feed the internal slave cylinder. You will need to match the year of your truck, not the transmission because the master cylinder bore diameter changed in 1993 if memory serves correct.

This may not hold true for 4x4 transmissions, but with my 4x2 swap, the crossmembers are different 4-speed to 5-speed, however it appears that both 5-speeds use the same one. The crossmember I picked up from the junkyard is stamped "4.9/5.0/5.8 M5OD" and came from an F150 - fits the ZF perfectly. I also needed the brackets that connect the crossmember to the upper side of the frame. I also had to swap the floorpan/transmission tunnel cover. The ZF would not fit under the original one, but again I think these are the same for all 5-speeds since I used one from an F150.

A driveshaft from an F250/350 will not be a plug-and-play swap. I had a driveshaft from an F250 with the same wheelbase as my F150 and due to the larger 10.25" axle, the rear half of the two piece driveshaft was about 3" too short. I think I spent about $150 on re-tubing and balancing the rear half.

I re-used the original flywheel, clutch, pressure plate, and starter from the 4-speed. I installed a new Motorcraft slave cylinder for an '88 F250 (couldn't use '87 since the ZF came out in '88 - master cylinders were the same 87-88).

According to the application chart on ZF's website, it shows that ZFs were installed in F150s in 1988 model year only, behind 4.9 and 5.8 engines in 4x2 configuration. I imagine finding one of these would be like a needle in a hay stack. https://www.zf.com/na/content/media/...ion_Charts.pdf

I had to switch the speedometer drive gear from 8 tooth to 7 tooth, but with 4x4 and electronic speedometer, you shouldn't have to worry about this at all.

Thats a lot of good info, thanks for posting that.

Whats the specs of your truck?
Why did you use the slave out of an '88? would the newer ones not work?
 
  #32  
Old 01-12-2016, 04:31 AM
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Since I left the original master cylinder in my truck, I wanted to get as close as possible to the same model year for the slave cylinder to minimize the chance that something changed, although I believe that the slave cylinder was the same up through '92 and changed when the master cylinder bore diameter changed in '93. A newer than '92 slave cylinder would not work with the original '87 master cylinder and a newer than '92 master cylinder to my knowledge would not fit the firewall on an '87.

What specs are you looking for?
 
  #33  
Old 01-12-2016, 08:30 PM
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Originally Posted by EPNCSU2006 View Post
Since I left the original master cylinder in my truck, I wanted to get as close as possible to the same model year for the slave cylinder to minimize the chance that something changed, although I believe that the slave cylinder was the same up through '92 and changed when the master cylinder bore diameter changed in '93. A newer than '92 slave cylinder would not work with the original '87 master cylinder and a newer than '92 master cylinder to my knowledge would not fit the firewall on an '87.

What specs are you looking for?
I was just reading about that, keeping the master and slave from the same yrs.

I asked the specs of your truck, but now I see you have an 87 302 4x2.
 
  #34  
Old 02-15-2016, 07:36 PM
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Just an update, picked up a zfs5-42 last night with cross member and a longer front shaft.
My four speed is 26" from bell to tail, and the zf is 29", so either way drive line work is going to be necessary.

Just to confirm, I will need a different tunnel cover for the zf?
 
  #35  
Old 02-15-2016, 10:07 PM
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  #36  
Old 02-16-2016, 12:01 PM
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If the tunnel cover doesn't have a step up at the very rear and a straight incline to the front, you'll need one for a 5-speed.
 
  #37  
Old 02-16-2016, 08:55 PM
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Originally Posted by EPNCSU2006 View Post
If the tunnel cover doesn't have a step up at the very rear and a straight incline to the front, you'll need one for a 5-speed.

Thanks.
Picked up a cover for a five speed today at a local yard.
Now time for the install and driveline work.
 
  #38  
Old 02-18-2016, 07:08 PM
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Will the t18 dust shield work with the zf?
 
  #39  
Old 02-19-2016, 04:52 AM
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Originally Posted by PRIMERED79 SHORT BED View Post
Will the t18 dust shield work with the zf?
No, not even close
 
  #40  
Old 02-19-2016, 05:18 AM
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Are you talking about the sheet metal piece that goes between the bell housing and the engine? I used the one off of my 4-speed when I swapped in the ZF and it lined right up.
 
  #41  
Old 02-19-2016, 05:37 AM
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[QUOTE=EPNCSU2006;16056983]Are you talking about the sheet metal piece that goes between the bell housing and the engine? I used the one off of my 4-speed when I swapped in the ZF and it lined right up.[/QUOTE

Lol one says no and one says yes.

Which four speed did you have and did you have a sbf bellhousing?
 
  #42  
Old 02-19-2016, 07:46 PM
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Does any body have a close up pic or part number for the plate I'll need for the zf?

This is the last part I need to get the swap finished.
 
  #43  
Old 02-20-2016, 05:54 AM
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[QUOTE=PRIMERED79 SHORT BED;16057002]
Originally Posted by EPNCSU2006 View Post
Are you talking about the sheet metal piece that goes between the bell housing and the engine? I used the one off of my 4-speed when I swapped in the ZF and it lined right up.[/QUOTE

Lol one says no and one says yes.

Which four speed did you have and did you have a sbf bellhousing?
No, the Dust Shield goes on the bottom of the bell housing to block fingers from getting in the flywheel
 
  #44  
Old 02-20-2016, 06:37 AM
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[QUOTE=Diesel_Brad;16059900]
Originally Posted by PRIMERED79 SHORT BED View Post

No, the Dust Shield goes on the bottom of the bell housing to block fingers from getting in the flywheel
That's what I'm trying to figure out, the one on my four speed in a one piece plate, but don't know if it will fit the zf.
Will any five speed work?
 
  #45  
Old 02-20-2016, 08:56 AM
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Originally Posted by PRIMERED79 SHORT BED View Post
That's what I'm trying to figure out, the one on my four speed in a one piece plate, but don't know if it will fit the zf.
Will any five speed work?
I don't know about your Windsor but I used the same one on my 460 when I swapped from BW T-19 to a ZF-5 S42
 

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